Closed cell foam sheets are often compared with EVA because both material families can be supplied as closed-cell foams. They are not the same polymer, and the finished behaviour depends on formulation, density, cross-linking and grade. All Foam currently sells AFP30 and AFP45 polyethylene foam, not EVA foam.
Quick answer
PE foam is based on polyethylene. EVA foam is based on an ethylene-vinyl acetate copolymer. Both can be lightweight, closed-cell and water resistant, but EVA often has a more rubber-like feel while polyethylene ranges from semi-rigid non-cross-linked packaging foam to rigid cross-linked grades. The exact grade matters more than the material name alone.
What is polyethylene foam?
Polyethylene, usually shortened to PE, is a polyolefin polymer.
Foamed polyethylene can be made in different ways.
Two examples in the All Foam range are:
- Ethafoam STPE200, a semi-rigid non-cross-linked expanded polyethylene packaging foam
- AFP30 and AFP45, rigid cross-linked closed-cell polyethylene foams
That immediately shows why "PE foam" is not one single feel or density.
What is EVA foam?
EVA stands for ethylene-vinyl acetate.
It is a copolymer made from ethylene and vinyl acetate. The amount of vinyl acetate and the foam formulation can change flexibility, resilience, hardness and surface feel.
EVA is widely used in products such as:
- sports mats
- footwear
- craft and cosplay foam
- protective inserts
- pads
- gaskets
- shaped components
All Foam does not currently offer EVA as an online product.
PE and EVA can both be closed cell
Closed cell describes the foam structure, not the base polymer.
That means it is possible to have:
- closed-cell PE
- closed-cell EVA
- closed-cell rubber foams
Calling two products "closed cell" does not make them interchangeable.
The polymer chemistry, density, hardness, cross-linking and test data still need to match the job.
Feel and flexibility
Many EVA grades are known for a smoother, more rubber-like and resilient feel.
PE foam varies widely.
Ethafoam STPE200 is semi-rigid.
AFP30 and AFP45 are rigid, dense cross-linked PE grades, with AFP45 denser than AFP30.
Do not use "PE is soft" or "EVA is always flexible" as universal rules. Manufacturers can formulate each material across a range of densities and hardnesses.
Packaging uses
Both material families can appear in protective packaging.
PE is widely used for:
- end caps
- separators
- case inserts
- blocks
- liners
- returnable dunnage
- edge protection
EVA is also used for presentation and protective inserts, particularly where a fine surface or resilient feel is wanted.
The best choice depends on the product and packaging system rather than which material sounds more premium.
Density is not the same as firmness
This distinction is important when comparing foam.
Density is mass per unit volume.
Firmness or hardness describes resistance to indentation or compression under a stated test.
A denser foam may often feel firmer within one product family, but it is not safe to compare two unrelated materials from density alone.
Always compare the actual test data where performance matters.
Cross-linked and non-cross-linked PE
PE itself also divides into different structures.
Ethafoam STPE200 is non-cross-linked.
AFP30 and AFP45 are cross-linked.
Cross-linking changes the polymer network and affects behaviour such as dimensional stability, conversion and end-of-life processing.
So a meaningful "PE vs EVA" comparison needs to state which PE grade is being discussed.
Water behaviour
Many closed-cell PE and EVA grades have low water absorption, which is one reason both are used in damp or protective applications.
Do not transfer a water-absorption value from one material to another.
For All Foam:
- AFP30 is described as waterproof and non-absorbent
- AFP45 has a maximum water absorption of 1% by volume
- STPE200 has 1.19% by volume after 24 hours under its stated test
An EVA supplier should provide the equivalent value for the exact EVA grade being considered.
Compression and recovery
Protective packaging depends on what happens when foam is compressed and then unloaded.
EVA is often selected where resilience and a more rubber-like recovery are desirable.
PE packaging grades can provide excellent support and impact control, but the correct design depends on the foam's compression behaviour and the load area.
Do not assume that the material with the stronger hand feel protects a fragile product better.
Packaging should be tested with the actual item and journey.
Surface finish and presentation
EVA is often chosen for display or retail inserts where a smooth fine-cell appearance is part of the presentation.
Cross-linked PE can also produce neat case inserts and defined cut shapes.
Ethafoam STPE200 has a different semi-rigid packaging character.
If visual finish is important, compare actual samples rather than relying on photographs from different manufacturers.
Cutting and conversion
Both PE and EVA can be cut and converted using appropriate processes.
The cleanest process depends on:
- density
- thickness
- cell structure
- required tolerance
- shape complexity
- production quantity
A tool that works well for thin craft EVA may not be appropriate for a thick rigid AFP45 sheet.
For commercial parts, use a conversion method suited to the exact foam and drawing.
Adhesive bonding
PE is a low-surface-energy plastic and can be difficult to bond with ordinary adhesives.
EVA is also classed among low-surface-energy material families in many bonding guides.
For either material, use a bonding system whose manufacturer specifically approves the exact substrate and the second material.
Do not assume an adhesive labelled "foam glue" suits both.
Heat forming and welding
Some PE and EVA grades can be heat-formed or laminated using specialist converting processes.
The correct temperature and process depend on the material.
Do not apply a heat-forming temperature from EVA craft foam to an AFP30, AFP45 or Ethafoam industrial part.
For repeat converted components, use a supplier or fabricator with a controlled process for that grade.
Recycling differences
End-of-life options also depend on structure.
Non-cross-linked polyethylene is more straightforward to melt and reprocess than cross-linked polyethylene.
Cross-linked materials can require specialist mechanical or other recovery processes.
EVA recycling also depends on formulation, additives and local facilities.
Do not describe either material family as universally kerbside recyclable.
Which should you choose?
Choose from the application rather than the abbreviation.
Ask:
- How much load must the foam support?
- How much movement is acceptable?
- Is the part reused?
- Is surface presentation important?
- Is water exposure expected?
- Does the part need a specified hardness or compression value?
- How will it be cut or converted?
- Does it need to be bonded?
- Is a regulatory property required?
Then compare actual grades.
Why All Foam sells PE rather than calling everything EVA
All Foam's current closed-cell online range is deliberately specific.
AFP30 and AFP45 are polyethylene grades.
Ethafoam STPE200 is a separate semi-rigid packaging polyethylene grade.
Calling either product "EVA" would be technically wrong and could lead to the wrong material being specified.
If a drawing or customer specification explicitly calls for EVA, source the required EVA grade rather than substituting PE without approval.
Quick answers
Is EVA the same as polyethylene foam? No. EVA is an ethylene-vinyl acetate copolymer. PE foam is based on polyethylene.
Are both PE and EVA closed cell? They can both be made as closed-cell foams, but "closed cell" describes structure rather than polymer identity.
Which is firmer, PE or EVA? There is no universal answer because both families have different grades. Compare the exact density, hardness or compression data.
Is EVA better for packaging? Not automatically. The right material depends on load, fragility, reuse, presentation, conversion and cost.
Does All Foam sell EVA foam? No. The current relevant All Foam products are polyethylene grades, including AFP30, AFP45 and Ethafoam STPE200.
